Armature



Dec. 12, 1933. V APPLE 1,939,615

ARMATURE Filed Aug. 8, 1929 3 Sheets-Sheet l V. G. APPLE Dec. 12, 1933.

ARMATURE Filed Aug. 8, 1929 3 Sheets-Sheet 2 v. G. APPLE ARMATURE Filed Aug. 8, 1929 3 Sheets-Sheet 3 IN VE N TOR, (ff

Patented Dec. 12 1933 UNITED STATES 1,939,615 ARMATURE Vincent G. Apple, Dayton, Ohio; Herbert F. Apple, Edward M. Apple, and Gourley Darroch, executors of'said Vincent G. Apple, deceased Application August 8,1929. Serial No. 384,404.

7 Claims. (CL-171+206i This invention relates to armatures for dynamo electric machines and particularly to armatures having a wire winding embedded and en-- the wire is yet pliable, then shape the mass of wire concentrictothe armature axis and harden it in this shape, in order that a better running l5 balance may be maintained Another specific object of the invention is to so proportion, arrange and treat the conductive elements of the structure as to facilitate the application of the insulation jacketthereto.

Another specific object is to so cement together the core, the coils and the commutator as tomake ofv them a self supporting structure which: does not dependronthe armature shaft for axial alignment of the parts, to the end that the shaft may be removed or renewed at will.

Further and-still .moreispecific objects will be apparent to those skilled in the art as the invention is described in detailand reference mad to the drawings in which- I Fig. 1 shows a plurality of'laminaa assembled on a mandrelto compose a core.

Fig. 2 is an end viewx'of the core after it is wound, and leads are brought, out radially from the inner sides of. the coils. i

Fig. 3 is a section taken on the line 3-3 of Fig.2. I M

Fig. 4 is a perspective view 'of a completed'commutator. J 1

Fig. 5 is anfl'autline of a'sheet'metal blank used to makea commutator :segment.

Fig. 6 shows a commutator. segment made from a blank Fig.5.

Fig. '7 is an axialsection taken at 7-"lof Fig.1

I 8 to show how the leads,brought from the inner sides of. the coils, extend .along'the segment risers to their outeriends where. they are connected thereto. I

. Fig. 8 isa transverse section taken at 8-8 of Fig. '7.

Fig. 9 shows 5 how the segment risers are bent down to their final position to cover the leads;

Fig. 1.4 axial section through "a" mold adapted to apply the jacket of :molded. insulation, the wound armature being in placezwith a proper. quantity of unmolded-compound, reach to be timed and compressed into a layer around;

thewinding. i

:Fig. 15 is anaxialsection throughthe mold. after the insulation jacket is pressed about thewinding T Fig. 16 shows the completed armature:

Similar numerals refer to similar parts throughout the several viewa. v a 'i To successfully mold a'ja'cket of plastic insula-z tion around. a structure containing a fine wire winding, the existence of several conditions is more or less essential. Y

First, the turns of the winding should be surrounded with. an adhesive insulating material which. may be hardened so as to make the coils about which the jacket is afterward to be molded as rigid as possible, sothatwery little relative. shifting between adjacent turns of the coils may take. place when thepressure incident to molding ing that azconsiderable layer of, itextends' be-;

, tween' all adjacent turns, and betweenthe turns and the core, so that, when the jacket is being molded, should slight-relativeshiftingtake place between adjacent wires, .or between wires and the core, the layer of insulation therebetween may not be brokendown to permitshorting between turnsor grounding to the core.

Third, the said adhesiveinsulating material should be of such high: quality and of such a nature that it maynot be forced by pressure from between two wires or other surfaces once a suitable layer has been placed therebetween and hardened. '1 I a Fourth, it is highly important that no flnewire leads should extend unsupported across open spaces, from the general mass ofthe hardened coils to spaced apart terminals; such as'commutator bars, etc, because the plastic material afterward :molded about; the coils to form the jacket may tearaway -such unsupported leads when it'moves past. and around them during the moldingoperation. g

The structure and the procedure hereinafter described attain the objects of the invention by;

meeting the foregoing conditions.

The core'20 Fig.1 having winding apertures 21 separated by teeth 22 is, composed of a, plurality of laminae 23 compacted uponthe stem24 of mandrel '25 and held compacted byginsulation collar 26,

metal 'collar2'7, and'nut 28. .A, keyway 29 in stemv 24' isentered by corresponding integral .keys 30 in. laminae 23; whereby; alignment of the the core. Thereare two coils per aperture and a apertures of one lamina with another is maintained. I I

I Before a winding is placed in apertures 21they should be lined with insulation, preferably by applying aheavy coating of liquid insulation to the inside of theapertures and hardening it, though;

the apertures may be insulated by lining them with fishpaper or the like in the'usual manner.

The mandrel 25 remains in the coreuntil the armature is completed' In order to surround the turns of the wire of the armature coils with a suitable layer of adhesive insulation, which may be afterwardhardened to provide rigid coils, the procedure described in my'copending application Serial No. 356,586, filed April 19th, 1929, is preferably adopted. This procedure oonsists. essentially of drawing .wire which already has a coating of fibrous or other absorptive; insulation through a receptacle conpregnating them, may be employed as a step in carrying out this invention when combined with other novel features disclosed.

"Figs. 2 and3 show the'wound structure 31 comprising the core 2.0 with coils 32in the apertures 21 and coilheads 33 and 34 extending beyond lead 35 composed of two coil ends twisted together is brought outfrom the inner side of each coil where it rests against insulation collar 26 i and is extended radially outward as shown.

'To make a suitable commutator 36 a procedure similar to that shown and described and claimed inmy copending application. Serial No. 363,460, filed May 16th,. 1929, may profitablybe adopted, although other means may beemployed if desired. This procedure consists essentially in providing commutator segments with risers, providing a mold with pockets to fit the risers, clamping the risers of the segments in'the mold pockets to hold the brush track parts of the segments spaced apart, and molding a core of insulation between I and about the'se'gments: to compose a commu- Fig 6.

tator.

Blanks 3'7, Fig.5, out from conductive material of suitable thickness are pointed as at 138 and notched asat -39. commutator segments 40 are then made by bending at right angles to provide a brush track portion 41 and a riser42 with the pointed'ends 38 turned under as shownin Fig. 4 shows the commutator made by binding together the proper number of segments 40 with" the core 43 of insulation. Core 43 has an axial opening 44 and integral key 45 of substantially the same dimensions as the corresponding openings and keys in the core laminae 23. Core 43 extends outwardly between the segments to the brush trackand for that reason should preferably be composed of a material which will not carbonize under the arcing of brushes. i I a Having; provided the wound structure 3l fand the commutator 36, thenut 28 and the metal. .001-

l'ar 27 are removed from. stem 24 and the commutator put on the stem in place of the collar,

.then the nut is returned to hold the commutator in place; 7 I

Figs. 7 and 8 show how the leads 35 extend radially between the coilhead 33 and the risers 42 to their outer ends where they are wound aroundthe-ends of the risers in the grooves 39 and soldered, welded or otherwise joined. When soldering is the method selected the height of the risers permits their outer ends to be dipped in a pot of molten solder without danger of getting any of the solder into the winding. 7

After the leads are alllaid along the sides of the risers and connected as shown in Figs. 7 and 8, a layer of treated tape 46 may be laid over coil of plastic insulation is molded thereabout, a numb er. of advantaeesmay be gained by holding the winding in a definite shape While it is being hardened, first, because, by drawing the coils and coil heads into ci-rcularform concentricwith theaxis of rotation and so hardening them, a better me- .chanical balance may be had and the jacket over them will be of more uniform thickness, and second, because, if the jacket is to'be molded around both 'coil heads, ata single operation, passages whereby the plastic insulation may pass from one.

end of the core to the other must be provided.

Such passages are preferably provided by keeping vacant a portion ofeach winding aperture 21 at its outer edge.

The envelope 47,",Figs. 10 and 11, is made in two halves 48 and. 49 held tightly by nut '50 and has cupped ends 51 and 52, an opening 53for mandrel 2.5 to extendthrough, an opening 54 for commutator 3.6v to extend through, and a series of inwardly extending keys 55 to enter theouter edges of apertures 21 to press'the coils inwardly. and com-pactthem more closely into the bottoms of the apertures and thereby leave spaces at the.

outer. edges of the apertures after the coils. are

hardened. v r

Figs. 12 and .13 :show'the armature in the en velope, and it is readily seen how keys '55 keep the coils 32 down in the apertures and. how cupped ends 51 and 52 keep the coil heads to concentric shape while the armature is being hardened.

When the armature hasbeen baked for a suitable period in envelope 4?, it is removed and placed in mold 56. Mold 56 comprises a base 57, a body 58 and a plunger 59. Base 57 is bored at 6.0 to. clearthe nut 28 and'counterbored at 61 to receive the commutator :36 andis held concentric with body 58 by annular rib 62. Body 53'is bored smoothly at the lower end as at .63 to a diameter. adapted toreceive the commutator 36, next above this at 64 to a diameter ,sufiiciently larger than the coil head 33 tov admit a layer of plastic insulation whichis to form thejacket arou'ndihnoxt above this to a smooth diameter 65 whichwill uniformly distributed throughout the mass; A

is then put in the opening 67 around the. coil head 34 and mandrel 25 and the plunger 59 is entered above the compound as shown in Fig. 14.

Pressure from any suitable source is now put on plunger 59 and maintained until the compound absorbs suflicient heat from the mold, plunger, and core to flux it, whereupon the applied pressure will forcethe plunger downward, pressing the fluid insulation around coil head 34, downwardly through the outer portions of winding apertures 21 which were left vacant by the keys when envelope 47 was removed, and farther downward around coil head 33 surrounding and covering the bent over risers 42 (see Fig. 15).

Whenthe mold has been held closed as in Fig. 15 for a sufilcient length of time to permit the heat of the mold to harden the jacket of insulation the armature is removed from the mold and the mandrel, 25 is removed from the armature,

jacket of insulation to be molded over them without danger of breaking the leads from the coils or from the risers.

Second, making the segment risers extend outwardly beyond the armature diameter, joining the leads to the outer ends, dipping the said outer ends into a solder pot without getting the core, coils, or commutator in the solder, then bending the leads down to bring them to a diameter smaller than the. armature, facilitates the soldering operation.

Third, hardening the coils in an envelope of the character shown and described brings their mass to more concentric relation with the axis of rotation of the armature, and insures a better running balance.

Fourth, providing internal keys in the envelope which extend into the outer parts of the winding apertures while the coils are being hardened, insures free passage of plastic compound from one end of the core to the other when the jacket is being molded around the coils. I

Fifth, the same ring of insulation which forms a jacket over the front coil head also holds the inner ends of the commutator segments against radial outward movement from centrifugal force by surrounding the segment risers.

And sixth, the same said ring of insulation which forms a jacket over the front coil head and surrounds the segment risers, joins the commutator and the armature together and holds then in axial alignment, so that these two members need not depend on the armature shaft to perform this function, as in common practice.

tively high and thin commutator segment risers and bending the said risers downward against. the coil head so that each riser completely covers a lead.

2. Steps in the method of making an armathe inside of ture of the character described, which consist of connecting the coil leads to the relatively high and thin commutator segment risers, said leads and the coil head being saturated with a cementitious insulation, bending the risers downwardly against the coil head so that each riser completely covers a lead, and hardening the cementitious insulation to aflix the leads and bent over risers.

3. Steps in the method of making an armature, which consist of joining the coil leads to the outer ends of the relatively high and thin commutator segment risers at points radially beyond the core, dipping the joints into molten solder, then bending the risers over to a diameter smaller than said core.

4. Steps in the method of making a balanced armature having a slotted core and a winding comprising a plurality of turns of insulated wire,

' which consists of saturating the winding with a fluid insulation, pressing the coil sides downe wardly toward the bottoms of the coreslots all to the same depth from the outer surface of the core and the coil heads into a symmetrical shape concentric with the armature axis, hardening tween the leadsand the commutator, which consists of assembling the core and winding, providing a commutator having relatively thin bend able risers, assembling the wound core and the commutator, connecting the fine wire leads to the underside of the risers, bending the risers over against the winding heads, one riser over each fine wire lead, to protect the leads against the movement of the plastic insulation to be molded about the winding head, then compressing the jacket of plastic insulation over the risers and about the winding heads to enclose them.

6. The method of balancing an armature comprising a slotted core and a wire. winding having normally unbalanced winding heads and coil sides normally seated at varying depths in their respective core slots, which consists of saturating the winding with a liquid insulating cement to make it pliable, drawing the unbalanced coil heads to a symmetrical shape concentric with the armature axis and at the same time pressing the coil sides downward in the slots all to the same depth from the outer surface of the core, and

hardening the cement while the coil heads and coil sides are being held' in said shape.

7. For holding the liquid insulation saturated winding of a dynamo electric machine armature concentric with its slotted magnetic core while said insulation is being hardened, apparatus comprising, in combination, a separable envelope having one of its inside diameters adapted to fit said core snugly and smaller inside diameters concentric with the first said diameter adapted to surround the winding closely, internal keys on the mold wall adapted to extend into thecore slots to a uniform depth, and means to hold the separable parts of said envelope together while said insulation is being hardened.

VINCENT G. APPLE.

100 the insulation while the winding is pressed in 

